Abstract
Molding composites constituted of fiber reinforcements, resin and fillers is of prime interest for many transportation applications. Dealing with the flow of particle-filled resin in a fibrous network raises the issue of particle retention and viscosity increase. The present study aims at simulating such molding through an efficient coupling between a filtration model, that has been previously described, and a flow model (Darcy’s law). First, filling experiments are realized so as to separate cases: cake filtration, retention and no retention for two types of single-scale porous materials (polyester felt and glass fiber mat) injected with a resin filled with micro-beads. Then results of filler content, viscosity, permeability, pressure, retention profiles are simulated from the coupling between filtration and flow. Experimental data of filler profiles in the final parts, resin flow front evolution and injection times are compared with predictions obtained from the simulation.
Highlights
Some large and complex shaped composite parts are produced using Liquid Composite Molding processes (LCM), such as Resin Transfer Molding (RTM) or Liquid Resin Infusion (LRI)
This paper proposes to simulate the injection molding of a composite part consisting of a fiber reinforcement, fillers and resin that includes flow, filtration and material property evolution
The modification of fiber volume fraction, filler content and particle diameter influenced the flow of the suspension in the porous media
Summary
Some large and complex shaped composite parts are produced using Liquid Composite Molding processes (LCM), such as Resin Transfer Molding (RTM) or Liquid Resin Infusion (LRI). In such technologies, a dry fibrous preform is first placed in a mold and the liquid resin is forced through it. It has previously been stated that the suspension viscosity increases when: the filler content increases [8,4], small particles rather than coarse ones are used [19], irregular shaped, rough surfaced particles rather than smooth spherical ones are employed [11].
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